Reliability Engineering

Rajesh V. R. Asst. Professor Dept. of Mechanical Engg. FISATTM

Module 3

Intro

The rapidly increasing global competition over the past decade has led to the emergence of new scenarios for most of the industrial sectors Rapid technological changes and product variety proliferation in order to remain competitive The competitiveness of a company is mostly dependent on its ability to perform well in dimensions

such as cost, quality, delivery, dependability and speed, innovation and flexibility to adapt itself to variations in demand

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Intro

To improve the organizational performance through the effective use of production capability and technology, Operations Strategies used are:

total quality management (TQM) Six Sigma just in time (JIT) quality function deployment (QFD) business process re-engineering (BPR) Benchmarking etc..
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Reliability and Quality

The Difference

Quality and reliability are not the same Quality includes efficiency, accuracy, aesthetic standards in addition to reliability Reliability factor is the important factor amongst the quality factors Quality is the degree to which a device meets various standards specified for it

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Quality Control

While reliability is concerned with the performance of a product over its entire lifetime, quality control is concerned with the performance of a product at one point in time, usually during the manufacturing process Quality control is a single, albeit vital, link in the total reliability process Quality control assures conformance to specifications
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Quality - defined

Fitness of Use (Joseph Juran)

It is the value of the goods and services as perceived by the supplier, producer and customer

Quality is conformance to requirements (CROSBY) The efficient production of the quality that the market expects (DEMING) Quality is what the customer says, it is (FEIGENBAUM) Quality is the loss that a product costs to the society after being shipped to the customer (TAGUCHI)

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Dimensions of Product Quality

As prescribed by Garvin:

Performance Reliability Durability Serviceability Aesthetics like?)

(will the product do the intended job?) (how often the product fails?) (how long the product lasts?) (how easy is to repair the product?) (what does the product look

Features (what does the product do?) Perceived quality (what is the reputation of a company or its products?)
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Dimensions of Service Quality

Reliability Responsiveness Competence Courtesy Communication Credibility Security

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Historical Aspects of Quality

Edward Deming

Postulated Statistical QUALITY Control Principles 14 Points of QUALITY Management These Principles successfully adapted by Japanese Manufactures

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Historical Aspects of Quality

William Crosby

Emphasized Humanistic Behavioral Aspects of QUALITY Improvement Becoming More Important Now

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Historical Aspects of Quality

Joseph Juran's QUALITY Trilogy

A. QUALITY Planning

Set of QUALITY Goals Set Plans for Operations Based on these Goals Responsible for Meeting QUALITY Goals Prevent Adverse Changes Set and Observe

B. QUALITY Control

Performance Measures Compare with Industry Standards Benchmarking

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Historical Aspects of Quality

Joseph Juran's QUALITY Trilogy

C. QUALITY Improvement

Moving from Current Level to the Next Higher Level Organize Teams, Train Operators to identify and Correct QUALITY Problems

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Three Aspects of Quality

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Quality of Design: Consumer's Perspective

The product must be designed to meet the requirements of the customer The factors need to consider while designing the product are:

Type of product Cost Profit policy of the company Demand Availability of the parts Environmental consideration Intended life of the component
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Quality of Conformance: Manufacturer's Perspective

The product must be manufactured exactly as designed The activities involved at this stage include:

defect finding defect prevention defect analysis rectification

The difficulties encountered at the manufacturing stage must be conveyed to the designers for modification in design, if any
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Quality of Performance

The product must function as per the expectations of the customer The two way communication between designers and customer is the key to have a quality product

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Quality Costs
COST

Prevention Cost

Appraisal Cost

Internal Failure Cost

External Failure Cost

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Quality Costs

Cost to meet the costumers quality needs Includes market research costs to field service costs

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Cost of prevention

Costs associated with the personnel engaged in designing, implementing and maintaining quality system Costs incurred in the process of trying to prevent defects and errors from occurring These costs are involved for:

planning the quality control process training and educating designing the product for quality designing the production system for quality preventive maintenance
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Cost of Appraisal (detection costs)

This cost is to assure conformance with the quality standards and performance requirements Costs of determining the current quality of the production system or inspection and testing through sampling The costs involved are for

measuring and testing parts and materials conducting statistical process control receiving inspection reporting on quality
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Cost of Internal Failures

Costs associated with the defective products, components and materials that fail to meet quality requirements Costs incurred when defects and errors are found before shipment or delivery to the customer The costs involved are for

labor and materials that are scrapped reworking and retesting to correct defects lost profits
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Cost of External Failures

Costs associated with the shipping of defective items to the customers Or the costs of trying correct defects and errors after receipt by the customer The costs involved are for

quick response to complaints adjustments to correct the problem lost goodwill warranties and insurance settlements of lawsuits product recall
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Manufacture for Quality and Reliability

Reliability & Quality Assurance programme:

Planning to achieve desired quality Project organisation, planning & scheduling Quality & reliability requirement Reliability & safety analysis Selection of materials & processes to get the set quality Quality test Quality reporting system
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TQM

Based on the ideas of W. Edward Deming, Philip B. Crosby, and Joseph M. Juran Total quality management (TQM) is a management philosophy and strategy designed to involve all members of an organization in the process and responsibility for producing quality products and services
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TQM

It is based on the participation of all the members of an organisation, aiming at long term success thru customer satisfaction This approach is, therefore, customer oriented Focuses on the quality of processes that are carried out in the organisation
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TQM

TQM was first associated with the Toyota production system Companies using a total quality management system typically incorporate

just-in-time production (JIT) systems business process reengineering, analyzing and redesigning the work environment traditional quality systems such as ISO 9000
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8 Principles of TQM

Customer-oriented

Define quality in terms of customers and their requirements

Leadership Strategic planning

Stress objectives rather than subjective measurement and analysis Make quality everyones responsibility

Employee responsibility

Continuous improvement Communication

Focus on process rather than output Fact Based Decision Making Integrated system
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Statistical methods

Training and education

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Demings 14 points on TQM

1.

2.

Create constancy of purpose toward improvement of product and service Adopt the new philosophy

We are in a new economic age

3.

4. 5. 6.

7.

Cease dependence on mass inspection to achieve quality Constantly and forever improve the system. Remove barriers Drive out fear. Create trust and a climate for innovation Break down barriers between departments
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Demings 14 points on TQM

8. 9. 10. 11. 12. 13.

Eliminate numerical goals

Eliminate work standards (quotas) Institute modern methods of supervision Institute modern methods of training Institute a program of education and retraining End the practice of awarding business based on lowest price alone Put everybody in the company to work to accomplish the transformation
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14.

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Deming Wheel: PDCA Cycle

4. Act
Institutionalize improvement; continue cycle.

1. Plan
Identify problem and develop plan for improvement.

3. Study/Check
Assess plan; is it working?

2. Do
Implement plan on a test basis.

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Criticisms to TQM

Goal of TQM as being designed to be motivational, in that it increases the responsibilities of the employees in the organization and widens the scope of their duties However, the reality is that the natural outcome of the organizational total quality management system is to drive the employee to work harder and longer hours thereby increasing the potential for incidences of stress-related illness
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Criticisms to TQM

Many organizations have found total quality management too deliberative and quantitatively oriented to utilize in fastchanging markets In quality management systems effectiveness is rarely assessed; most audits only check compliance.
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Strategic Implications of TQM

Strong leadership Goals, vision, or mission Operational plans and policies Mechanism for feedback

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ISO standards

Overview

The International Organization for Standardization (ISO) is a nongovernmental worldwide federation whose mission is to promote the development of standardisation ISO was formed in 1946 in Geneva ISO is a network of the national standards institutes of 160 countries, one member per country ISO is the world's largest developer and publisher of International Standards
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Overview

A standard is a basis for comparison

Or a reference point against which evaluation can be made

Standardisation is the process of establishing a technical standard, which could be a standard specification, standard test method, standard definition, standard procedure (or practice), etc. Standardisation is implemented greatly when companies release new products to market
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ISO 9000 series

The ISO 9000 family of standards represents an international consensus on good quality management practices It consists of standards and guidelines relating to quality management systems and related supporting standards Five standards related to Quality:

ISO 9000 ISO 9001 ISO 9002 ISO 9003 ISO 9004

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ISO 9000

Provides guidelines for selection and use of ISO standards

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ISO 9001

Specifies requirements for a quality management system where an organization Model for quality in Design, Development, Production, Installation and Servicing Applies to industries who designs, manufacturers and provide sale after service also Examples are coolers, heat exchangers etc.

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ISO 9002

Model for Quality Assurance Production, installation and servicing Examples are civil structures

in

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ISO 9003

Model for Quality Assurance in Final Inspection and Test Examples are domestic appliances, petroleum products

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ISO 9004

Provides guidelines Administrative and affecting the Quality Services at all the stages It provide Guidelines improvements

for Technical, Human Factors of Products or

for performance

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ISO 14000

World wide approved model for Environmental Management System (EMS) Aims at environmental protection Provides standards to be followed to manage and improve environmental performance without affecting the business operation To have a healthier environment for all the companies irrespective of their size and purpose

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ISI or BIS

Indian Standards Institution was set up in 1947 BIS is a statutory organisation established under Bureau of Indian Standards Act ISI is the former name for BIS In BIS, standards are formulated thru technical committees These committees are having representatives form manufacturers, technical experts and users The standards are documents of consensus which are finalised after taking the views of all
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ISI or BIS

BIS has formulated nearly 17000 standards, which may be categorised as:

Basic standards Product specifications Method of tests and codes of practices

BIS has established a chain of labs at different centres in the country

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Procedure for BIS(ISI) certification

1.
2. 3.

4.

Apply for certification at BIS Document review by the BIS officials Audit at site Issue of certificate on conformance with the standards

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Prototyping

Prototypes are models of a system or component These are made for the purpose of demonstrating performance and functionality Useful in demonstrating design aspects

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Need for Prototyping

Enables ideas to be tested thru trial and error method

This enables the rectification of errors in the design stage

Helps to develop procedures for the products to be manufactured Helps to detect errors while interpreting engineering drawings Used to demonstrate new product to the customers
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Rapid Prototyping

Rapid prototype represents an incomplete model of the system to be developed It is quite useful when the physical system similar to the one to be developed is not available for comparison It represents the key parts of the system It is simple and inexpensive to produce Customer is allowed to experiment with the prototype to assess the functionality of the component Changes are possible in the prototype until the required product is developed
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Rapid Prototyping

Rapid prototyping

takes virtual designs from CAD or animation modeling software transforms them into wireframe model of horizontal cross sections then creates each cross section in physical space one after another

It can produce models in a few hours; although the time can vary widely depending on the type of machine being used and size and no: of units
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Sequencing

Process of arranging the operations or jobs to be performed in the machines such that there is less idle time for the entire operations Its purpose is to achieve maximum profit by optimum utilisation of machines

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Assumptions in Sequencing

Each machine can not handle more than one operation at a time Once an operation is commenced, it should continue till its completion in the same machine No parts should be processed separately by more than one machine at a time The time for processing an operation is independent of the order in which operations are performed There is only one of each type of machine All the jobs are known and ready for processing The time for transferring the jobs between the machines is negligible
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Sequencing

Process of arranging the operations or jobs to be performed in the machines such that there is less idle time for the entire operations Its purpose is to achieve maximum profit by optimum utilisation of machines

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